Method and apparatus for loading bobbin cores

ABSTRACT

A method and apparatus for loading a bobbin core from a plurality of bobbin cores onto a bobbin winding device. A plurality of stacked bobbin cores are received into a first end of a first chute. The first chute has a second end positioned adjacent to a rotatable hub. A bobbin core from the plurality of stacked bobbin cores in the first chute is received into a bobbin core holder on the rotatable hub. The rotatable hub is then rotated with hub driving means such that the bobbin core holder on the rotatable hub moves from the second end of the first chute to a first end of a second chute, the first end of the second chute being positioned adjacent to the rotatable hub. The second chute also includes a second end positioned adjacent to the bobbin winding device. The bobbin core previously received into the bobbin core holder is then dispensed onto the bobbin winding device by passing the bobbin core through the second chute.

FIELD OF THE INVENTION

The present invention relates generally to systems for winding threadsor yarns onto winding cores. More particularly, the present inventionrelates to automatic systems for loading and dispensing individualwinding cores onto a winding device. Still more particularly, thepresent invention relates to a system for loading and dispensing emptybobbin cores onto dental floss winding machines.

BACKGROUND OF THE INVENTION

Tooth decay and dental disease can be caused by bacterial actionresulting from the formation of plaque about the teeth and/or theentrapment of food particles between the teeth and intersticestherebetween. The removal of plaque and entrapped food particles reducesthe incidence of caries, gingivitis, and mouth odors as well asgenerally improving oral hygiene. Conventional brushing has been foundto be inadequate for removing all entrapped food particles and plaque.To supplement brushing, dental flosses and tapes have been recommended.The term "dental floss", as used herein, is defined to include bothdental flosses, dental tapes and any similar article.

Dental floss is typically distributed in dispensers that have circularbobbins rotatably mounted therein. Each bobbin is formed of a core thathas been wound with dental floss. The tail end of floss from the bobbinis typically threaded first through an eyelet at the top of thedispenser and then through a cut bar that is also positioned at the topof the dispenser. In order to draw a length of floss from the dispenser,a user grasps the tail end of the floss, pulls until the desired lengthof floss has been drawn from the dispenser, and then cuts the drawnlength using the cut bar. As the user pulls the floss from thedispenser, the bobbin in the dispenser rotates, thereby allowing thefloss on the bobbin to unwind.

During the manufacturing of dental floss products, automated windingmachines are used to wind floss onto empty bobbin cores. These automatedwinding machines typically use a mounting apparatus such as a windingarbor for receiving and holding bobbin cores during the winding process.Each winding arbor must typically be loaded with an empty bobbin coreprior to the time any floss is wound on the bobbin core. It is possibleto perform this bobbin core loading operation manually, however, the useof labor for this operation is undesirable from a cost point of view.

It is therefore an object of the present invention to provide anefficient and cost-effective system for loading empty bobbin cores ontowinding arbors in an automated fashion.

It is a further object of the present invention to provide an automatedsystem for loading bobbin cores one-at-a-time onto winding arbors.

It is a still further object of the present invention to provide abobbin core loading system which can monitor and verify that bobbin coreloading has occurred.

It is a still further object of the present invention to provide abobbin core loader that is resistant to jamming.

These and still other objects of the invention will become apparent uponstudy of the accompanying drawings and description of the invention.

SUMMARY OF THE INVENTION

The present invention is directed to a method and apparatus for loadinga bobbin core from a plurality of bobbin cores onto a bobbin windingdevice. A plurality of stacked bobbin cores are received into a firstend of a first chute. The first chute has a second end positionedadjacent to a rotatable hub. A bobbin core from the plurality of stackedbobbin cores in the first chute is received into a bobbin core holder onthe rotatable hub. The rotatable hub is then rotated with hub drivingmeans such that the bobbin core holder on the rotatable hub moves fromthe second end of the first chute to a first end of a second chute, thefirst end of the second chute being positioned adjacent to the rotatablehub. The second chute also includes a second end positioned adjacent tothe bobbin winding device. The bobbin core previously received into thebobbin core holder is then dispensed onto the bobbin winding device bypassing the bobbin core through the second chute.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a worms eye view of a bobbin core loading device in accordancewith a preferred embodiment of the present invention.

FIG. 2 is a front view of a bobbin core loading device in accordancewith a preferred embodiment of the present invention.

FIG. 3 is a rear view of a bobbin core loading device in accordance witha preferred embodiment of the present invention.

FIG. 4 is a flow diagram illustrating the operation of a bobbin coreloading device in accordance with a preferred embodiment of the presentinvention.

FIG. 5 is a block diagram showing a hub drive controller in accordancewith a preferred embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring now to FIGS. 1-3, there are shown worms-eye, front and rearviews, respectively, of a bobbin core loading device 100 in accordancewith a preferred embodiment of the present invention. Loading device 100is formed of a block 110 having several tubular passages within itsinterior. In particular, block 110 has a first tubular chute 120 forreceiving stacked bobbin cores 125 into the top of loading device 100.Block 110 also includes a second tubular chute 130 for dispensing orloading empty bobbin cores one-at-a-time onto a winding device (notshown).

A rotatable hub 140 is positioned between the receiving chute 120 andthe dispensing chute 130. The receiving chute 120 has a first end 120aat the top of loading device 100 and extends therefrom to its second end120b which is positioned adjacent to rotatable hub 140. Dispensing chute130 has a first end 130a positioned adjacent to rotatable hub 140.Dispensing chute 130 extends from its first end 130a to its second end130b which is preferably positioned above a winding device.

Rotatable hub 140 is connected to a pneumatic actuator 145 by a drivingpin 150. Driving pin 150 defines the axis of rotation of rotatable hub140. Rotatable hub 140 is preferably formed of a cylindrical block andhas a cylindrical opening 155 which is perpendicular to the perimeter ofhub 140. Opening 155 has a depth 155a that is approximately equal to thethickness of a bobbin core 125, and a diameter 155b that isapproximately equal to the diameter of a bobbin core 125. Opening 155defines a bobbin core holder.

During operation of loading device 100, stacked bobbin cores 125 arecontinually received into receiving chute 120 through end 120a. Thestacked bobbin cores 125 are then carried one-at-a-time by bobbin coreholder 155 from end 120b of receiving chute 120 to end 130a of dispenserchute 130. This carrying step is accomplished by first aligning bobbincore holder 155 under end 120a of receiving chute 120 until a singlebobbin core 125 falls (by gravity) into bobbin core holder 155, and thenrotating hub 140 in a clockwise direction along an angular distanceequivalent to the angle theta shown in FIG. 2. When rotatable hub 140reaches the end of this angular rotation, bobbin core holder 155 will bepositioned adjacent to and aligned with end 130a of dispensing chute130. As bobbin core holder 155 rotates into alignment with end 130a, thebobbin core 125 within bobbin core holder 155 will fall (by gravity)into and then through the dispensing chute 130. In the preferredembodiment, following the dispensing of a bobbin core 125 through thedispenser chute 130, hub 140 then rotates in a counterclockwisedirection along an angular distance equivalent to the angle theta shownuntil bobbin core holder 155 again comes into alignment under end 120aof receiving chute 120 and a further bobbin core 125 falls (by gravity)into bobbin core holder 155. In the preferred embodiment, the processdescribed above is then repeated sequentially in order to dispenseindividual bobbin cores 125 through dispenser chute 130 at regularintervals.

Although in the preferred embodiment, bobbin core holder 155successively moves from end 120b to end 130a and then from end 130a toend 120b by an oscillatory motion that includes alternating clockwiseand counterclockwise movements, it will be understood by those skilledin the art that core holder 155 could alternately move from end 120b toend 130a and then from end 130a to end 120b by rotating eithersequentially or continuously in a single angular direction.

The rotation of hub 140 is preferably driven by a pneumatic actuator145, although any standard motor may be used. In the preferredembodiment, pneumatic actuator 145 drives hub 140 such that bobbin coreholder 155 moves first clockwise from end 120b to end 130a and thencounterclockwise from end 130a to end 120b in a time period of 0.01 to0.50 seconds. Also in the preferred embodiment, the oscillation ofbobbin core holder from end 120b to end 130a and then back from end 130to end 120b is repeated 30-40 times per minute, thus allowing coreloader 100 to dispense up to 40 individual cores one-at-a-time perminute through end 130b.

In order to prevent jams from occurring within chutes 120 or 130, thesechutes should preferably be formed of smooth metal surfaces and shouldhave diameters that closely approximate the diameter of a bobbin core125. In a preferred embodiment, the diameters of chutes 120 and 130 arewithin 0.005" of the diameter of a bobbin core 125. Although the presentinvention is designed to prevent the jamming of bobbin cores 125anywhere within loading device 100, openings 160a and 160b are providedalong the front face of block 110 thereby giving an operator easy accessto the interiors of the receiving chute 120 and dispensing chute 130 inorder to clear any jams that may occur in the device. In order toprevent cores 125 from passing through the openings 160a, 160b duringoperation of the device, openings 160a, 160b have a width that is lessthan the diameter of a bobbin core 125.

In order to verify the proper operation of core loader 100, the presentinvention includes several sensors for monitoring different aspects ofthe operation of the device. In particular, a pair of magnetic sensors170a, 170b are affixed to the rear of core loader 100. Sensor 170a ispositioned behind end 120b and is used for sensing and verifying thatbobbin core holder 155 is aligned with end 120b. Similarly, sensor 170bis positioned behind end 130a and is used for sensing and verifying thatbobbin core holder 155 is aligned with end 130a. An optical sensor 180(formed of a light source 180a and an optical receiver 180b) ispositioned near the base of chute 130. As shown in FIG. 5, the outputsfrom sensors 170a, 170b and 180 are all coupled to a controller 190 forcontrolling the movement of pneumatic actuator 145.

Referring now to FIG. 4, there is shown a flow diagram illustrating theoperation of a bobbin core loading device in accordance with a preferredembodiment of the present invention. The operation begins in step 210 bywaiting for a signal that a core winding device (such as a winding arborfor winding dental floss onto a bobbin core) is positioned belowdispenser chute 130. Upon receipt of a signal indicating that a windingarbor is in position, processing proceeds to step 220 where controller190 attempts to load a core by causing bobbin core holder 155 to rotatefrom end 120b to end 130a and then back from end 130a to end 120b.During this oscillation, controller 190 monitors the outputs of sensors170a and 170b to verify that a complete oscillation has actuallyoccured. If the output of sensors 170a and 170b indicate that a completeoscillation did not occur, then (in step 230) the core loader 100 isplaced in an off state; otherwise processing proceeds to step 240 wherethe output of sensor 180 is checked in order to verify that a bobbincore passed through chute 130. If sensor 180 was able to verify thepassage of a bobbin core 125 through chute 130, then processing proceedsto step 210 and the process is repeated. If sensor 180 was unable toverify the passage of a bobbin core 125 through chute 130, thenprocessing proceeds to step 250 where a determination is made regardingthe number of previous unsuccessful attempts that have made to load abobbin core 125. In step 250, the number of previous unsuccessfulattempts that have been made to load a bobbin core 125 is monitored andcompared against a threshold k. If the threshold number of unsuccessfulloading attempts has been reached, then the core loader is placed in anoff state; otherwise, processing proceeds to step 220 where a furtherattempt is made to load a bobbin core. In a preferred embodiment, k isset 1, although other values may alternatively be used.

The present invention may be embodied in other specific forms withoutdeparting from the spirit or essential attributes of the invention.Accordingly, reference should be made to the appended claims, ratherthan the foregoing specifications, as indicating the scope of theinvention.

What is claimed is:
 1. An apparatus for dispensing bobbin cores,comprising:(A) a first chute for holding a plurality of stacked bobbincores, said first chute having a first end for receiving said pluralityof stacked bobbin cores into said first chute, said first chute having asecond end positioned adjacent to a rotatable hub; (B) a second chutefor dispensing cores from said plurality of stacked bobbin cores onto abobbin winding device, said second chute having a first end positionedadjacent to said rotatable hub, said second chute having a second endpositioned adjacent to said bobbin winding device; (C) said rotatablehub having a bobbin core holder for carrying a bobbin core from saidplurality of stacked bobbin cores from said second end of said firstchute to said first end of said second chute; (D) hub driving means forrotating said bobbin core holder from said second end of said firstchute to said first end of said second chute; (E) first sensor means forverifying movement of said bobbin core holder from said second end ofsaid first chute to said first end of said second chute; and (F) secondsensor means for verifying passage of a bobbin core through said secondchute.
 2. The apparatus of claim 1, further comprising:(G) a controller,coupled to said first and second sensor means and said hub drivingmeans, for controlling said hub driving means.
 3. The apparatus of claim2, wherein said first sensor means is comprised of a first magneticsensor positioned adjacent to said second end of said first chute and asecond magnetic sensor positioned adjacent to said first end of saidsecond chute.
 4. The apparatus of claim 3, wherein said second sensormeans is comprised of an optical sensor positioned along said secondchute.
 5. The apparatus of claim 4, wherein said bobbin winding deviceis a winding arbor for winding dental floss.
 6. A method for loading abobbin core form a plurality of bobbin cores onto a bobbin windingdevice, comprising the steps of:(A) receiving said plurality of stackedbobbin cores in a first chute, said first chute having a first end forreceiving said plurality of stacked bobbin cores into said fist chute,said first chute having a second end positioned adjacent to a rotatablehub; (B) receiving into a bobbin core holder on said rotatable hub abobbin core from said plurality of stacked bobbin cores; (C) rotatingwith hub driving means said bobbin core holder on said rotatable hubfrom said second end of said first chute to a first end of a secondchute, said first end of said second chute being positioned adjacent tosaid rotatable hub, said second chute having a second end positionedadjacent to said bobbin winding device; (D) dispensing said bobbin corereceived in step (B) onto said bobbin winding device by passing saidbobbin core through said second chute; (E) after said dispensing step,rotating with said hub driving means said bobbin core holder on saidrotatable hub from said first end of said second chute to said secondend of said first chute; (F) repeating steps (B) through (F) for aplurality of cycles; (G) verifying with first sensor means movement ofsaid bobbin core holder during step (C); and (H) verifying with secondsensor means passage of said bobbin core through said second chute instep (D).
 7. The method of claim 6, wherein said first sensor means iscomprised of a first magnetic sensor positioned adjacent to said secondend of said first chute and a second magnetic sensor positioned adjacentto said first end of said second chute.
 8. The method of claim 7,wherein said second sensor means is comprised of an optical sensorpositioned along said second chute.
 9. The method of claim 8, whereinsaid bobbin winding device is a winding arbor for winding dental floss.